End shield for a commutator machine and a method for producing such an end shield

Abstract

A bearing plate for a commutator machine according to the related art is made of metal and comprises an applied brush holder made of plastic. Connector elements for electrical components on the brush holder are inserted in corresponding receptacles in the brush holder in a separate working step, however. In the bearing plate ( 1 ) according to the invention, the connector elements ( 4, 8, 11 ) are formed out of the bearing plate and are partially connected to the bearing plate ( 1 ), thereby reducing the number of parts to be installed as well as the production expense.

1 . Bearing plate ( 1 ) made of metal for a commutator machine ( 46 ) that has the following features: 
 i) the bearing plate ( 1 ) closes a housing ( 48 ) of the commutator machine ( 46 ) on the front side,    ii) the bearing plate ( 1 ) forms a bearing receptacle ( 43 ) for a bearing ( 51 ) of a rotor shaft ( 53 ) of the commutator machine,    iii) the bearing plate ( 1 ) is connected to a brush holder ( 62 ), whereby the brush holder ( 62 ) has the following features: the brush holder ( 62 ), when the bearing plate ( 1 ) and housing ( 48 ) are in the assembled state, is situated on an inner surface of the bearing plate ( 1 ) and is electrically insulating, the brush holder ( 62 ) has guide shafts to accommodate one commutator brush ( 56 ) each in radially displaceable fashion, characterized in that at least one electrically conductive connector element ( 4 ,  8 ,  11 ) for electrical components ( 68 ) or plugs ( 76 ) are formed out of the bearing plate ( 1 ).    
     
     
         2 . Bearing plate according to  claim 1 , characterized in that at least one connector element ( 4 ,  8 ,  11 ) is a single piece with the bearing plate ( 1 ).  
     
     
         3 . Bearing plate according to  claim 1  or  2 , characterized in that the brush holder ( 62 ) is injection-moulded or cast onto the bearing plate ( 1 ) as an integral part of the bearing plate ( 1 ).  
     
     
         4 . Bearing plate according to one or more of the claims  1  through  3 , characterized in that at least one connector element ( 4 ,  8 ,  11 ) is partially embedded in the brush holder ( 62 ) and partially protrudes out of the brush holder ( 62 ).  
     
     
         5 . Bearing plate according to one or more of the preceding claims  1  through  4 , characterized in that an attachment housing ( 75 ) for an external electrical connection is designed as a single piece with the brush holder ( 62 )  
     
     
         6 . Bearing plate according to one or more of the claims  1 ,  3  through  5 , characterized in that the brush holder ( 62 ) is made of a heat-resistant material in the area of the guide shafts ( 59 ).  
     
     
         7 . Bearing plate according to one of the preceding claims  1 ,  3  through  6 , characterized in that the brush holder ( 62 ) is made of plastic.  
     
     
         8 . Method for producing a bearing plate ( 1 ) out of metal for a commutator machine ( 46 ) that has the following features: 
 i) the bearing plate ( 1 ) closes a housing ( 48 ) of the commutator machine ( 46 ) on the front side,    ii) the bearing plate ( 1 ) forms a bearing receptacle ( 43 ) for a bearing ( 51 ) of a rotor shaft ( 53 ) of the commutator machine ( 46 ),    iii) the bearing plate ( 1 ) is connected to a brush holder ( 62 ), whereby the brush holder ( 62 ) has the following features: 
 the brush holder ( 62 ), when the bearing plate ( 1 ) and housing ( 48 ) are in the assembled state, is arranged on an inner surface of the bearing plate ( 1 ) and is electrically insulating, the brush holder ( 62 ) has guide shafts ( 59 ) to accommodate one commutator brush ( 56 ) each in radially displaceable fashion, characterized in that the bearing plate ( 1 ) with openings ( 44 ), the bearing receptacle ( 43 ), and connector elements ( 4 ,  8 ,  11 ) are first made out of sheet metal, then a slit extending through the bearing plate ( 1 ) is formed along corresponding parting lines ( 20 ) around the connector elements ( 4 ), so that each of the connector elements ( 4 ) is connected to the bearing plate ( 1 ) only along one connecting line ( 23 ), then at least one connector element ( 4 ) is bent along a bending line ( 17 ) out of a plane parallel to the bearing plate ( 1 ) into a desired shape to form connector elements ( 4 ,  8 , 11 ), whereby the connector elements ( 4 ) form an angle of up to 90° with this plane, then the brush holder ( 62 ) is connected-at least partially encompassing the connector elements ( 4 ,  8 ,  11 )—to the bearing plate ( 1 ), and then at least one connector element ( 4 ,  8 , 11 ) is separated at a first section ( 27 ), whereby a direct connection with the bearing plate ( 1 ) is broken at at least one connector element ( 4 ,  8 ,  11 ).  
   
     
     
         9 . Method for producing a bearing plate ( 1 ) out of metal for a commutator machine ( 46 ) that has the following features: 
 i) the bearing plate ( 1 ) closes a housing ( 48 ) of the commutator machine ( 46 ) on the front side,    ii) the bearing plate ( 1 ) forms a bearing receptacle ( 43 ) for a bearing ( 51 ) of a rotor shaft ( 53 ) of the commutator machine ( 46 ),    iii) the bearing plate ( 1 ) is connected to a brush holder ( 62 ), whereby the brush holder ( 62 ) has the following features: the brush holder ( 62 ), when the bearing plate ( 1 ) and housing ( 48 ) are in the assembled state, is arranged on an inner surface of the bearing plate ( 1 ) and is electrically insulating, the brush holder ( 62 ) has guide shafts ( 59 ) to accommodate one commutator brush ( 56 ) each in radially displaceable fashion, characterized in that the bearing plate ( 1 ) with openings ( 44 ), and the bearing receptacle ( 43 ) are first made out of sheet metal, connector elements ( 4 ,  8 ,  11 ) are also made out of sheet metal, then the connector elements ( 4 ,  8 ,  11 ) are connected to the bearing plate ( 1 ) in such a fashion that each of the connector elements ( 4 ) is connected to the bearing plate ( 1 ) along a connecting line ( 23 ), then at least one connector element ( 4 ) is bent along a bending line ( 17 ) out of a plane parallel to the bearing plate ( 1 ) into a desired shape to form connector elements ( 4 ,  8 , 11 ), whereby the connector elements ( 4 ) form an angle of up to 90° with this plane, then the brush holder ( 62 ) is connected-at least partially encompassing the connector elements ( 4 ,  8 ,  11 ) to the bearing plate ( 1 ) and then at least one connector element ( 4 ,  8 ,  11 ) is separated at a first section ( 27 ), whereby a direct connection with the bearing plate ( 1 ) is broken at at least one connector element ( 4 ,  8 ,  11 ).    
     
     
         10 . Method according to  claim 8  or  9 , characterized in that an attachment housing ( 75 ) with the brush holder ( 62 ) is produced in one work operation.  
     
     
         11 . Method according to one or more of the claims  8  through  10 , characterized in that the brush holder ( 62 ) is injection-moulded or cast onto the bearing plate ( 1 ) out of plastic ( 2 ).  
     
     
         12 . Method according to one of the claims  8  through  11 , characterized in that a heat-resistant plastic is injection-moulded in the region of the guide shafts ( 59 ) of the brush holder ( 62 ).  
     
     
         13 . Method according to one of the claims  8  through  12 , characterized in that the brush holder ( 62 )—after it is connected to the bearing plate ( 1 )—is completely assembled in that interference suppression means ( 68 ), brushes ( 56 ), brush leads ( 65 ), capacitors are installed and are connected to the connector elements ( 4 ,  8 ,  11 ) in electrically conductive fashion.